I'm just curious if anyone knows what will happen if you don't punch the extra hole in the gasket? The reason why I ask is I put one together before reading up on it and missed the extra hole in the pump. it seems to be working fine, Thanks in advance for your thoughts.

I just ordered a kit myself. I only have one actual Kawi pump, the rest have been standard Mikuni. I was losing fuel on the top end running. I've never had the standard pump fill the motor with fuel, however. Lucky I guess.

On that note, are the 2 diaphragms separate that have that large aluminum piece with the o-ring? Mine seem to be stuck together? Or does it screw together?

Your needles and seats must be in good shape. I had an intruder fill the crankcase once when I trailered it. it had the factory pump, it was pretty depressing to drive 4 hours to find the sled hydro locked.

I've never had one hydro lock on me. I have had them flooded from all the bouncing because of the bumpy roads. I no longer trailer my sleds when full of gas but wait until I get where I am going to fill them.